Installation Manual - Weil-McLain · PDF fileGAS-FIRED WATER BOILER — Installation...

• Selection data

• Installation

• Piping

• Water treatment

This manual must only be used by a qualified heating installer/service technician.Before installing, read all instructions, including this manual, the Ultra BoilerManual and all applicable Supplements. Consider all connections to the boilersbefore selecting a location and layout. Failure to comply could result in severepersonal injury, death or substantial property damage.

Part No. 550-101-232/0703

Gas-firedwater boiler

Installation Manual

with

Multiple-boiler systems withWeil-McLain Easy-Fit® piping

Part number 550-101-232/07032

GAS-FIRED WATER BOILER — Installation Manual — Multiple-boiler Systems

Contents

Hazard definitions.................................................................................................................................. 3

Selection dataControls .................................................................................................................... 3Domestic hot water ................................................................................................. 3Venting and combustion air.................................................................................... 3Additional considerations ....................................................................................... 3

Ratings and engineering data.................................................................................................................................. 4

Dimensions.................................................................................................................................. 6

Placement and mounting information.................................................................................................................................. 7

Easy-Fit® PipingEasy-Fit® Piping installation .................................................................................... 8Piping schematic ...................................................................................................... 9Easy-Fit® Piping 3-dimensional drawing ............................................................. 10Easy-Fit® Piping, 4 boilers, 3 water heaters, 3-dimensional .............................. 11Easy-Fit® Piping with isolation exchanger 3-dim. drawing ............................... 12

Combustion air and vent piping installationVent piping ............................................................................................................ 13Combustion air piping .......................................................................................... 13Combustion air manifolds .................................................................................... 13

Gas pipingConnecting gas supply piping .............................................................................. 14Common gas piping installation.......................................................................... 15

Additional instructionsAir for boiler room ventilation ............................................................................. 16Wiring ..................................................................................................................... 16Water treatment ................................................................................................... 16

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The following defined terms are used throughout this manual to bring attention to the presence of hazards ofvarious risk levels or to important information concerning the life of the product.

Hazard definitions

ControlsWeil-McLain offers an excellent selection of boiler sequencing controls. Refer to individual manuals for details.

Domestic hot waterRefer to Weil-McLain Piping Guides and PLUS Water Heater Manual and Ultra PLUS Supplement for suggestedpiping diagrams.

Venting and combustion airUltra boilers must be vented individually. Combustion air must be piped to the boiler as well, butmay be manifolded as shown on page 13. Follow Weil-McLain Ultra Boiler Venting Supplement andBoiler Manual plus information in this manual. Failure to comply will result in severe personal injuryor death.

Additional considerations1. Review the Ultra Boiler Manual and applicable supplements prior to designing and installing multiple-

Ultra-boiler jobs.

2. Ultra boilers are design-certified for installation on combustible flooring (not carpet).

3. Ultra boilers are tested for 30 P.S.I. working pressure (higher pressure not available).

4. For systems requiring greater than 30 P.S.I. relief valve setting, install a heat exchanger to isolate the boilers fromthe main system. See page 12 for suggested piping.

5. Maximum operating temperature of each boiler is 190°F.

This manual provides general guidelines for piping and installation. Your installation must complywith all applicable local codes.

When using isolation valves on each boiler, some codes may require providing a low water controland additional limit for each boiler. If desired, consult the codes to determine if exclusion of theindividual boiler isolation valves may allow the use of a single water level control and additionallimit for the entire multiple boiler system.

Selection data

Indicates presence of hazards that willcause severe personal injury, death orsubstantial property damage.

Indicates presence of hazards that cancause severe personal injury, death orsubstantial property damage.

Indicates presence of hazards that will orcan cause minor personal injury orproperty damage.

Indicates special instructions oninstallation, operation or maintenancethat are important but not related topersonal injury or property damage.

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Ratings and engineering data

Figure 1 Ratings and engineering data (see page 5 for notes)

DOE

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For simplicity, the table on page 4 lists only systems using multiples of the same Ultra boiler module.Any combination of Ultra boilers can be installed as a multiple boiler system.

Figure 1 Ratings and engineering data (continued)

Notes

1. Based on standard test procedures outlined by DOE forindividual boilers.

2. Net I=B=R ratings are based on piping and pickup allow-ance of 1.15. Consult Technical Services for other allow-ances.

3. Foundation sizes above provide 6 inches between boilersand 2 inches from boiler to edge of foundation. Smallerfoundations are possible with reduced service clearances.See Ultra Boiler Manual for details.

For side-to-side installations, see Figure 3, page 7.

For back-to-back installations, see Figure 4, page 7.

4. Operating weight is the total weight, including water.

5. Ultra-230 boilers can be vented with 3-inch vent insteadof 4-inch, with the limitations described in the Ultra BoilerVent Supplement. (Using the smaller vent pipe reducesmaximum allowable run.)

All Ultra installations require a separate vent pipe andtermination for each boiler. Vent piping cannot bemanifolded. Install and terminate vents as described inthe Ultra Boiler Vent Supplement.

Combustion air piping can be individually piped ormanifolded, as described on page 13. See Ultra Boiler VentSupplement for individual air piping.

6. Total amp requirements include boiler circulators.

Water header pipingDetermine the flow rate that the system header and otherpipes will handle. Then use the table at right to determinethe minimum pipe size. This table shows pipe sizing bothfor 350 and 500 milinches per foot head loss. Other pipesizing using recognized engineering would be acceptable.

Gas pipingSee pages 14 and 15 for gas piping requirements andconnections.

Part number 550-101-232/07036


1. Boiler supply and return tappings are both 1" NPT.Connect to headers with 1” pipe for Ultra-80 andUltra-105; 1¼" pipe for Ultra-155 and Ultra-230.For wall-hung boilers, water piping and gas pipecan be routed through bottom of enclosure usingwall-mounting kit.

Dimensions

Figure 2 Dimensional data

2. Boiler circulator is shipped loose. Mountboiler circulator in connecting pipingas shown in this manual. Boiler isshipped with 1" and 1¼" circulatorflanges.

3. Relief valve is shipped loose. See BoilerManual pages 14 and 15 for mountingdetails. Relief valve mounts on ¾" streetelbow connected to 1" x 1" x ¾" tee onboiler supply pipe, as shown in manual.

Notes

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Placement and mounting information

Placement, general1. Locate multiple boilers in boiler

room according to:

• Figure 3 (side-to-side), or

• Figure 4 (back-to-back).

For wall mounting, see below.

2. Provide indicated clearancesaround boilers for access andservicing. If recommended di-mensions are not possible, re-fer to Ultra Boiler Manual forminimum clearances. Also fol-low local codes.

3. Construct boiler foundation ifboiler room floor is uneven orif there is a danger of flooding.Size foundation to allow forclearance and spacing dimen-sions shown in either Figure 3or Figure 4.

4. Chalkline boiler locations onfoundation or boiler roomfloor.

5. Uncrate, assemble and mountboilers according to UltraBoiler Manual.

6. Provide clearance for installa-tion of venting, air piping, gaspiping, expansion tank, primarycirculator and other accessories.

Wall mounting1. Ultra boilers may be wall

mounted, following the instruc-tions in the Ultra Boiler Manualand the Wall Mounting Supple-ment.

2. When wall mounting boilers,provide approximately 6 inchesbetween boilers for easy re-moval of boiler jacket door. SeeFigure 5.

3. Follow all applicable codes re-garding piping, electrical con-nections and clearances.

4. When wall mounting boilers,verify the wall construction issuitable for the structural load.

Figure 3 Side-to-side installation of multiple Ultra-80/-105/-155/-230 boilers

Figure 4 Back-to-back installation of multiple Ultra-80/-105/-155/-230 boilers

Figure 5 Wall mounting multiple Ultra-80/-105/-155/-230 boilers

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Easy-Fit® Piping

Figure 6 Single-sided connection —Maximum connected boiler output: 2-inch manifolds — 450 MBH 3-inch manifolds — 1400 MBH 4-inch manifolds — 2900 MBH

Figure 7 Double-sided connection —Maximum boiler output (each side): 2-inch manifolds — 450 MBH 3-inch manifolds — 1400 MBH 4-inch manifolds — 2900 MBH

Easy-Fit® Piping installation1. Main header and Easy-Fit® Manifold pipe sizing.

a. New system:Refer to Figure 1 on pages 4 and 5 for recommendations.

b. Replacing boilers in an existing system:

Without reducing size, connect system supply and return lines.Install tees or crosses for Easy-Fit® Manifolds as shown in Figure 6or 7. Size manifolds to handle total connected boiler ouput as shown.

2. Provide connections in main header for Easy-Fit® Manifolds as close aspossible to the midpoint of multiple boilers.

a. Use tees for four or less boilers, as in Figure 6.b. Use either tees (Figure 6) or crosses (Figure 7) for five or more boil-

ers.

3. Manifold placement:

a. To alternate spacing for supply and return lines to boilers, reverse theshort-end and long-end of the Manifolds as shown in Figures 6 and7.

b. Return Manifold must be on the return side of the main and Sup-ply Manifold must be on the supply side of the main. Drawings inthis manual show flow in system main from right to left. For sys-tem flowing left to right, reverse the locations of the Manifoldsaccordingly.

4. Connect from Easy-Fit® Manifold branches to boiler supply and re-turn connections using 1¼" nominal copper tubing or steel pipe (maxi-mum run 15').

5. Provide a flow/check valve in the supply piping of each boiler as shownin piping diagrams in this manual. Install an isolation valve on thesupply and return of each boiler as shown. Some local codes may re-quire the use of individual level controls and limits on each boilerwhen isolation valves are installed.

6. Install main system air eliminator and primary circulator in supplypiping as shown in piping diagrams. Place expansion tank on suctionside of system circulator as shown.

7. Install condensate drain line piping according to Ultra Boiler Manual.Condensate drain piping may be connected into a manifold beforeconnection to a floor drain.

8. Install system accessories as shown in drawings.

9. For some applications, it may be necessary to install a heat exchangeras shown in Figure 11, page 12, to isolate the boilers from the system. Seenotes on page 12 for typical applications.

10. Piping recommendation drawings:

a. Figures 6 and 7 show details of Easy-Fit® Manifolds.b. Figure 8 is a schematic piping drawing showing the locations of typi-

cal boiler piping and system piping, including limits and other de-vices often required by local codes.

c. Figures 9 and 10 are three-dimensional piping drawings of typicalmultiple boiler installation.

d. Figure 11 shows recommended piping when an isolating heat ex-changer is needed.

11. If desired, other primary/secondary piping arrangements can be used.

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Figure 8 Piping schematic — Typical piping for multiple Ultra boilers, using Weil-McLain Easy-Fit® Manifolds

1 Flow/check valve (each boiler) 2 Isolation valves (when used) 3 Cap 4 Easy-Fit® Manifold (supply), sized per Fig. 6

or Fig. 7, page 8 5 Easy-Fit® Manifold (return), sized per Fig. 6

or Fig. 7, page 8 6 Primary circulator 7 Expansion tank (diaphragm type)

8 System air eliminator 9 System automatic air vent10 Pressure reducing valve11 Check valve or backflow preventer, as

required by applicable codes12 Isolation valve13 Cold water supply14 Supply water temperature control (when

used)

15 Low water cutoff (when used) (place aboveprimary header)

16 Water flow switch (when used)17 Boiler circulator (each boiler)18 System supply19 System return20 Boiler relief valve and discharge piping, installed

per Ultra Boiler Manual

This manual provides general guidelines for piping and installation. Your installation must comply with all applicable localcodes.

When using isolation valves on each boiler, some codes may require providing a low water control and additionallimit for each boiler. If desired, consult the codes to determine if exclusion of the individual boiler isolation valvesmay allow the use of a single water level control and additional limit for the entire multiple boiler system.

Part number 550-101-232/070310


Figure 9 Typical piping for multiple Ultra boilers, using Weil-McLain Easy-Fit® Manifolds

Easy-Fit® Piping (continued)

1 Flow/check valve (each boiler) 2 Isolation valves (when used) 3 Caps 4 Easy-Fit® Manifold (supply), sized per Fig. 6


or Fig. 7, page 8

6 Primary circulator 7 Expansion tank (diaphragm type) 8 System air eliminator 9 System automatic air vent13 Cold water supply17 Boiler circulator (each boiler)

18 System supply19 System return20 Boiler relief valve and discharge piping,

installed per Ultra Boiler Manual

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Figure 10 Typical piping for multiple Ultra boilers, Weil-McLain Easy-Fit® Manifolds, and indirect water heaters

1 Flow/check valve (each boiler) 2 Isolation valves (when used) 3 Caps 4 Easy-Fit® Manifold (supply), sized per Fig. 1


or Fig. 2, page 6 6 Primary circulator 7 Expansion tank (diaphragm type) 8 System air eliminator 9 System automatic air vent13 Cold water supply

17 Boiler circulator (each boiler)18 System supply19 System return20 Boiler relief valve and discharge piping,

installed per Ultra Boiler Manual21 Indirect-fired storage water heaters (Weil-

McLain PLUS Line shown) — Example isshown with reverse-return boiler-side pipingusing a single circulator. Alternate: each waterheater could have its own circulator.

22 Boiler water inlet23 Boiler water outlet24 DHW boiler-side circulator

25 DHW boiler-side supply Easy-Fit® Manifold26 DHW boiler-side return Easy-Fit® Manifold27 Flow/check valves (to prevent induced or

gravity flow in heating system or DHW piping)28 Check valve to prevent heat migration in

heating system29 See water heater manual for DHW piping —

The DHW piping must also be manifoldedtogether since the boiler-side piping ismanifolded. If DHW heaters supply separateDHW circuits, provide an individual circulatorfor each water heater, and control eachcirculator by its water heater’s aquastat.

This piping is suggested only. The layout above should be controlled with a boiler sequencing panel that provides DHW operation aswell. Wire the heating system circulator to operate only on call for heat. Alternatively, use the boiler sequencing panel to providedomestic priority by disabling the heating system circulator any time there is a DHW call for heat. The boiler circulators, item 17, mustoperate on any call for heat, whether heating system or DHW. Offset the DHW boiler-side supply and return manifolds as shown sothe total run of pipe and fittings to each of the water heaters is approximately equal.

Suggested DHW boiler-side pipe sizing (basedon 500 milinch per foot head loss in piping):

0 – 7 gpm .......................... 1 inch7 – 16 gpm ........................ 1¼ inch16 – 24 gpm ...................... 1½ inch24 – 45 gpm ...................... 2 inch45 – 75 gpm ...................... 2½ inch75 –140 gpm ..................... 3 inch140 – 290 gpm .................. 4 inch

Part number 550-101-232/070312


Figure 11 Typical piping for multiple Ultra boilers, using Weil-McLain Easy-Fit® Manifolds and heat exchanger

Use isolation heatexchanger for:1. Large volume systems with high

mineral content in water.

2. Systems exposed to untreated quan-tities of makeup water.

3. Old systems severely contaminatedwith scale and rust buildup insidepiping and heat distribution units.

4. Process applications.

5. Commercial service water applica-tions.

6. High water pressure applications,requiring pressure relief setting inheating system more than 30 PSIG(tall buildings). See notes below.

1 Flow/check valve (each boiler) 2 Isolation valves (when used) 3 Cap 4 Easy-Fit® Manifold (supply), sized per Fig. 6


or Fig. 7, page 86a Heating system circulator (exchanger

tubeside)6b Heat exchanger shellside circulator 7 Expansion tanks (diaphragm type) 8 System air eliminator

9 System automatic air vent13 Cold water supply connections17 Boiler circulator (each boiler)18 Heating system supply19 Heating system return20 Boiler relief valve and discharge piping,

installed per Ultra Boiler Manual

Notes:

1. Contact heat exchanger manufacturer forheat exchanger shellside and tubeside pip-ing and circulator requirements. Tubeside

flow and temperatures must meet heatingsystem requirements.

2. Contact heat exchanger manufacturer forsizing heat exchanger.

3. Heat exchanger shellside circuit requiresits own expansion tank as shown.

4. Heating system circuit requires its own ex-pansion tank, as shown, plus its own re-lief valve set to protect heating system andheat exchanger piping and components.

5. When individual isolation valves are used,individual boiler and level controls maybe required.

Easy-Fit® Piping (continued)

Part number 550-101-232/0703 13


Figure 12 Manifolding combution air piping

Combustion air & vent piping installation

Vent piping

1. Each boiler requires an individual vent pipe, in-stalled and terminated per the Ultra Boiler Manualand Ultra Boiler Venting Suppments.

2. The vent pipes of multiple boilers must terminate onthe same side of the building as their air inlet piping,and per all requirements of the Ultra Boiler Manualand Vent Supplements.

Combustion air piping1. Provide combustion air piping to each boiler, fol-

lowing all requirements for installation and termi-nation per the Ultra Boiler Manual and Ultra BoilerVenting Supplements.

2. Combustion air piping can be supplied from acommon combustion air manifold, installed andterminated as shown in Figure 12, below.

Combustion air manifolds1. When combustion air supplied from a common air

manifold pipe as in Figure 12, size the common airduct and louver free area from the minimum freearea given in Figure 1, pages 4 and 5.

2. All joints must be sealed.

3. The air inlet must be located:

• at least 3 feet below any vent located within 10feet.

• the louver bottom must be 12 inches above gradeor above the snow line.

4. Compensate for louver blockage when calculatingfree air openings. Refer to manufacturer’s instruc-tions for size. If unknown use:

a. Wood louvers — 20-25% free area.b. Metal louvers or grilles — 60-75% free area.

5. Lock open louvers or interlock with boiler controlsto open automatically with boiler operation.

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Figure 13 Connecting gas supply piping

Gas piping

Connecting gas supply piping1. Remove jacket front panel and refer to Figure 13 to

pipe gas to boiler.

a. Install ground joint union for servicing, whenrequired.

b. Install manual shutoff valve in gas supply pip-ing outside boiler jacket when required by lo-cal codes or utility requirements.

c. In Canada — When using manual main shut-off valve, it must be identified by the installer.

2. Wall-mounted boilers

a. Refer to separate Ultra Boiler Wall-mountinginstructions.

b. Gas connection may enter from the bottom ofboiler as explained in the Wall-mounting in-structions.

3. Support piping with hangers, not by boiler or itsaccessories.

4. Purge all air from gas supply piping.

5. Before placing boiler in operation, check boiler andits gas connection for leaks.

a. Close manual main shutoff valve during anypressure testing at less than 13" w.c.

b. Disconnect boiler and gas valve from gas sup-ply piping during any pressure testing greaterthan 13" w.c.

Do not check for gas leaks with an openflame — use bubble test. Failure to usebubble test or check for gas leaks can causesevere personal injury, death orsubstantial property damage.

6. Use pipe dope compatible with propane gases.Apply sparingly only to male threads of pipe jointsso that pipe dope does not block gas flow.

Failure to apply pipe dope as detailedabove can result in severe personal injury,death or substantial property damage.

DO NOT adjust or attempt to measuregas valve outlet pressure. The gas valve isfactory-set for the correct outlet pressure.This setting is suitable for natural gas andpropane, requiring no field adjustment.Attempting to alter or measure the gasvalve outlet pressure could result indamage to the valve, causing potentialsevere personal injury, death orsubstantial property damage.

Ultra boilers are shipped ready to firenatural gas ONLY. You must install thepropane orifice if the boiler will beconnected to propane. Failure to complycould result in severe personal injury, deathor substantial property damage.

Use two wrenches when tightening gas piping at boiler, using one wrench to prevent the boiler gasline connection from turning. Failure to support the boiler gas connection pipe to prevent it fromturning could damage components.

Part number 550-101-232/0703 15


Figure 14 Common gas piping, with manifolded gas header

Common gas piping installation

4. Size gas piping from meter outlet to entrance of gas header inaccordance with Tables 1 and 2 below. For gases with otherspecific gravity or for different pressure drop or other pipesizes, refer to the National Fuel Gas Code or applicable localcodes.

Pipe lengths in Table 1 are equivalent length of straight pipe.Convert pipe fittings to equivalent lengths using data fromTable 2.

5. Refer to page 14 of this manual and to the Ultra Boiler Manualfor testing gas piping.

1. Construct gas header for multiple boilers using Figure 14 andthe sizing tables below. Refer to the National Fuel Gas Code forother conditions.

2. Provide manual shutoff gas valve and ground joint union asshown in Figures 13 and 14 for each boiler. When gas line en-ters from top of the boilerl, the boiler internal gas piping pro-vides a drip leg. See boiler manual for details.

3. A ¾" NPT gas piping riser from header to boiler will belarge enough for most jobs. Check pressure drop.

Table 1 Capacity of gas piping for gas at 0.60 specificgravity at a pressure drop of 0.30 inches w.c.

Table 2 Equivalent lengths of straight pipefor typical gas line fittings

Part number 550-101-232/070316


Additional instructions

Air for boiler room ventilation1. Follow instructions in Ultra Boiler Manual to ensure the boiler room provides sufficient

air infiltration.

Wiring1. Refer to boiler sequencing control instructions and Ultra Boiler Manual for wiring re-

quirements.

Water treatmentMultiple boilers used with large water volume systems will require watersoftening and conditioning. Consult a local water treatment company prior toinstallation for analysis and recommendations.

Initial fill water may contain enough minerals to produce damaging deposits.Additional untreated makeup water will increase scale buildup.

Contamination may also come from scale and rust buildup inside the pipingand heat distribution units of an older boiler system replaced with small multipleboiler units. The result can lead to loss of efficiency and component failure.

1. Follow proper start-up procedure for flushing any contaminants from the entire systembefore initial fill.

2. Hot water systems should not require makeup water after initial fill. Use manual feedwater systems or install a water meter to detect leaks.

3. Repair leaks — constant fill water will cause problems.

4. Refer to Ultra Boiler Manual for more information.

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